Packaging with Insulative Walls Having Condensation Wicking Layer and Bubble Foil Insulation Layer

ABSTRACT

A packaging may include at least one insulating wall and at least one cooling device embedded into the at least one wall. A method of forming at least one insulating wall of a package may include placing a cooling device into a form, closing the form, injecting a liquid form of an expansive foam, and curing the foam.

BACKGROUND

Package delivery has become a significant part of commerce in today'seconomy. Today, a vast majority of companies that sell products oftenhave those products available online and shipped to the purchaser. Thishas become increasingly true considering recent lockdowns pushed as areactionary measure during a world pandemic. In some instances, theproduct being shipped may be perishable and/or adversely affected tochanges in temperature.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate various examples of the principlesdescribed herein and are part of the specification. The illustratedexamples are given merely for illustration, and do not limit the scopeof the claims.

FIG. 1 is a block diagram of a packaging according to an exampleembodiment of the principles described herein.

FIG. 2 is a block diagram of a packaging according to another exampleembodiment of the principles described herein;

FIG. 3 is a flowchart showing a method of forming at least oneinsulating wall of a packaging according to an example embodiment of theprinciples described herein;

FIG. 4 is a flowchart showing a method of forming at least oneinsulating wall of a packaging according to another example embodiment,of the principles described herein;

FIG. 5 is a block diagram of a shipping container according to anexample embodiment of the principles described herein;

FIG. 6 is a side cut-away view of an insulating walls according to anexample embodiment of the principles described herein;

FIG. 7 is a plan view of a plurality of insulating walls according to anexample embodiment of the principles described herein;

FIG. 8A is a top view of an open form used to form the insulating wallsaccording to an example of the principles described herein;

FIG. 8B is a top view of an open form used to form the insulating wallsaccording to another example embodiment of the principles describedherein;

FIG. 8C is a top view of an open form used to form the insulating wallsaccording to another example embodiment of the principles describedherein;

FIG. 9 is a top plan view of the packaging according to another exampleof the principles described herein.

Throughout the drawings, identical reference numbers designate similar,but not necessarily identical, elements. The figures are not necessarilyto scale, and the size of some parts may be exaggerated to more clearlyillustrate the example shown. Moreover, the drawings provide examplesand/or implementations consistent with the description; however, thedescription is not limited to the examples and/or implementationsprovided in the drawings.

DETAILED DESCRIPTION

Shipping products across a geographical area includes packaging theproduct such that the product reaches the end consumer in the state thatthe consumer expects. Any damage to the products resulting from theshipping process may result in poor consumer satisfaction as well asreturned product at the cost of the shipper, the consumer, and/or themanufacturer of the product.

To alleviate any potential damage to the product being shipped, thepackaging used to ship the product in may be altered to prevent suchpotential damage. In an example, this may include adding a coolingdevice such as an ice pack in order to prevent overheating of certaintypes of products. However, the ice packs may limit the volumetriccapacity of the packaging as well as fail to provide adequate coolingover the transit period of the shipped product.

In some embodiments herein, the packaging may also include temperatureregulating layers. Among these temperature regulating layers may be abubble foil insulation layer. The bubble foil insulation layer may bemade of a heat reflective material that prevents the transfer of heatout from and into the package. With the inclusion of pockets of air inthe bubble foil insulation layer, the transfer of heat from within thepackage to the exterior or from outside the package into the interior isalso reduced. This extends the “operative lifetime” of the packaging byextending the time in which the package may be subjected to differentenvironments and temperatures. It may also better maintain a specifictemperature within the package despite those weather conditions.

In other embodiments, the packaging may also include a condensationwicking layer. This condensation wicking layer may absorb any water thatmay result in the slight changes in temperature or pressure within thepackage as the package is transported from one location to another.Indeed, changes in the water vapor pressure may change as, for example,when the package is transported via an airline or experiences changes inaltitude thereby effecting the amount of potential condensation that canform on the interior of the package.

The present specification describes a packaging including at least oneinsulating wall and at least one cooling device embedded into the atleast one wall. It is appreciated, however, that the packaging mayinclude a plurality of insulating walls with one or more cooling devicesembedded into those walls in order to cool the contents within thepackaging.

The present specification further describes a method of forming at leastone insulating wall of a package. In an embodiment, this may includeplacing a cooling device into a form; closing the form; injecting aliquid form of an expansive foam; and curing the foam. In anotherembodiment, the method of forming at least one insulating wall includesforming a bubble foil insulation layer on an outside surface of theinsulating wall. This includes placing a bubble foil insulation layer ona first side of a form, injecting a liquid form of an expansive foam;and curing the foam with or without the placement of the cooling deviceinto the form. In another embodiment, the method of forming at least oneinsulating wall includes forming a condensation wicking layer on anoutside surface of the insulating wall. This includes placing acondensation wicking layer on a second side of a form, injecting aliquid form of an expansive foam; and curing the foam with or withoutthe placement of the cooling device into the form. In anotherembodiment, the method of forming at least one insulating wall includesforming a bubble foil insulation layer on an outside surface of theinsulating wall and forming a condensation wicking layer on an outsidesurface of the insulating wall. This includes placing a bubble foilinsulation layer on a first side of a form, placing a condensationwicking layer on a second side of a form, injecting a liquid form of anexpansive foam; and curing the foam with or without the placement of thecooling device into the form.

The present specification also describes a shipping container, thatincludes a box; six insulating walls, at least one side of each of theinsulating walls laid against the surface of at least one wall of thebox, each of the insulating walls comprising: four chamfered edges; andat least one hinge between one of the four chamfered edges of a firstinsulating wall and a chamfered edge of a second insulating wall, thechamfered edge being a 47-degree chamfer; a bubble foil insulation layerformed onto an outer surface of each of the insulating walls; and acondensation wicking layer formed onto an inner surface of each of theinsulating walls.

As used in the present specification and in the appended claims, theterm “chamfer” is meant to be understood as a transitional edge betweentwo faces of an object. This chamfer edge, in an embodiment, may begreater than 45 degrees (e.g., 47 degrees) so that the edges of theindividual insulating walls are pressed together to form a seal at theedges.

Turning now to the figures, FIG. 1 is a block diagram of a packaging 100according to an example of the principles described herein. Thepackaging 100 may include an insulating wall 105. In an embodiment, thepackaging 100 may also include a cooling device 110. In anotherembodiment, the packaging 100 does not include a cooling device 110. Inan example, the packaging 100 may further include a box to encompass theinsulating wall 105.

The insulating wall 105 may be any type of wall that may help toinsulate a product from changes in temperature. In an example, theinsulating wall 105 may include a plurality of insulating walls 105 thatform a cube with an interior portion that is hollow. Although thepresent specification describes the packaging 100 as being a cuboidalshape, other shapes are also contemplated. The interior portion, duringuse of the packaging 100, provides for an object to be held therein. Theobject may be any type of object including both products to be shippedand, specifically, products that may be damaged due to changes intemperature had the packaging 100 not been present. By way of example,the product may be a chocolate product that, if subjected to an increasein temperature during transit, may melt damaging the quality and/ortaste of the chocolate. By way of another example, the product may be aglass jar full of perishable foodstuffs. In this example, it may bedisadvantageous for the glass jar to be subjected to extremely coldtemperatures sufficient to freeze the perishable foodstuffs therein andcausing the glass jar to break spilling the perishable foodstuffs in thepackaging 100. The insulating wall 105, in this example, may thereforeprevent the transmission of heat out of and into the packaging 100according to thermodynamic principles. It is to be understood in thepresent specification that, although the principles described herein usea cooling device 110 as a means of maintaining temperature within thepackaging 100, the principles described herein extend also to a heatingdevice used in connection with the insulating wall 105.

The insulating wall 105 may be made of any type of insulating material.In an example, the insulating wall 105 may be made of a foam. In anexample, the insulating wall 105 may be manufactured using any type ofexpansion foam that is presented in, for example, a form such as aliquid and is allowed to cure thereby creating an insulating wall 105according to the principles described herein. During the manufacturingprocess, the cooling device 110 may be incorporated into the insulatingwall 105 itself. In the example embodiment manufacturing processesdescribed herein, the cooling device 110 (or alternatively heatingdevice) may be placed within a certain location with a form before aliquid expansive foam is introduced into the form. As the expansive foamis introduced into the form, the liquid expansive foam forms around thecooling device 110 (or alternatively the heating device) and the coolingdevice 110 is embedded into the insulating wall 105 after curing of theliquid expansive foam thereby forming a monolithic piece.

In an example, the liquid expansive foam product may include a mixtureof a polyether polyol resin and a polymeric isocyanate. In this example,any type of polyether polyol resin and polymeric isocyanate may be usedbased on a number of criteria. These criteria include the length of timethat the packaging 100 is to be subjected to increases and/or decreasesin temperatures during transit of the packaging 100, the space availablewithin the packaging 100, the thickness of the insulating wall 105, thecuring time of the resulting expansive foam, among other criteria.

As shown in FIG. 1 , the packaging 100 may include a bubble foilinsulation layer 115. In an embodiment, the bubble foil insulation layer115 may include multiple layers that allow a gas or other fluid to beplaced within bubbled sections formed between the layers. In an example,the fluid held within the bubble sections of the bubble foil insulationlayer may be a polyatomic gas. In this embodiment, the polyatomic gasmay include those gaseous molecules that are not harmful to humans butthat store heat energy in other forms besides its kinetic energy therebycreating a thermal buffer between the elements and the interior voidformed by the insulating walls 105. In this example embodiment, whenheat energy is injected into this polyatomic gas, only part of that heatwill go into increasing their kinetic energy, and hence increasing thetemperature. A portion of the heat received at the polyatomic gas may gointo, for example, contributing to non-thermal movement of thepolyatomic molecules such as rotation of the molecules and vibration ofthe individual atoms relative to a center of mass of the polyatomicmolecule.

In one example embodiment, the bubble foil insulation layer 115 isformed by operatively coupling a flat polyethylene (LDPE) layer with abubbled layer of LDPE in order to trap a gas or other fluid between thelayers of LDPE. The flat layer of LDPE may be sealed to the bubble layerof LDPE so that the gas or other fluid does not escape. In thisembodiment, a reflective foil layer may be operatively coupled to theflat layer of LDPE. The reflective foil layer reduces radiant heattransmitted into the package 100. In an embodiment, the flat surface ofthe bubble foil insulation layer 115 that includes the flat layer ofLDPE may be affixed to an outer surface of the at least one insulatingwall 105. The inclusion of the bubble foil insulation layer 115 preventsradiant heat transmission into and out of the hollow formed by theplurality of insulating walls 105 formed into the cube packaging 100 asdescribed herein. By including this bubble foil insulation layer 115,the temperature within the packaging 100 may remain at a relativelyconstant temperature over time as the packaging 100 is shipped from onelocation to another. In an embodiment, the bubble foil insulation layer115 may be laminated on the outer surface of the plurality of insulatingwalls 105 during the formation process of the insulating wall 105 byplacing a layer of the bubble foil insulation layer 115 within the formused to form the insulating wall 105 prior to injection of the expansionfoam. In an embodiment, the inclusion of the bubble foil insulationlayer 115 on the packaging 100 allows for less materials used to formthe packaging 100. For example, by including the bubble foil insulationlayer 115, the thickness of the insulating walls 105 may be reduced dueto the increased insulative capabilities of the bubble foil insulationlayer 115. This reduction in the thickness of the insulating walls 105may or may not facilitate the inclusion of the cooling device 110 asdescribed herein and, in some embodiments, the cooling device 110 may beexcluded from the packaging 100.

As shown in FIG. 1 , the packaging 100 may include a condensationwicking layer 120. During use of the packaging 100, the packaging 100may be subjected to different temperatures, at different pressures, andat different dew points. These changes may result in the creation ofcondensation during transit of the packaging 100 as the packaging ismoved from land delivery vehicles, to delivery flights, and back again.The condensation wicking layer 120 may absorb an amount of condensationthereby preventing potential damage or spoiling of the products beingshipped. In an embodiment, the absorption rate and absorptioncapabilities of the condensation wicking layer 120 may be sufficient toprevent spoilage or damage of the product being shipped during theentire transit of that product.

The inclusion of the bubble foil insulation layer 115 on the outersurface of the insulating walls 105 and the condensation wicking layer120 on the inner surface of the insulating wall 105, the transit timeand distance may be extended. Due to the inclusion of the bubble foilinsulation layer 115, the temperature within the packaging 100 may bemaintained for a longer period of time. Due to the inclusion of thecondensation wicking layer 120, the changes in pressure, temperature,and dew point may be accommodated for allowing for more variedconditions under which the packaging 100 is subjected to as well asextending the duration of transit for the packaging 100.

In an embodiment, the packaging 100 may include the bubble foilinsulation layer 115 without the condensation wicking layer 120. Inanother embodiment, the packaging 100 may include the condensationwicking layer 120 without the bubble foil insulation layer 115. In yetanother embodiment, the packaging 100 may include both the condensationwicking layer 120 and the bubble foil insulation layer 115. Therefore,the inclusion or exclusion of either of the condensation wicking layer120 or bubble foil insulation layer 115 with the packaging 100 may bedriven by a number of factors including, but not limited to, thepurchasers shipping requirements, characteristic shipping requirementsassociated with the products being shipped in the packaging 100, as wellas weight considerations due to the inclusion or exclusion of either ofthe condensation wicking layer 120 or bubble foil insulation layer 115,among other factors.

Additionally, the present specification contemplates that the coolingdevice 110 may or may not be included within the packaging 100. Forexample, because the bubble foil insulation layer 115 provides anincrease insulative capabilities of the packaging 100, the insulatingwalls 105 may be made thinner. This may reduce the amount of spaceavailable within the thickness of the insulating walls 105 toincorporated a cooling device 110 therein. In this instance, othercooling devices may be placed within the hollow of the formed packaging100 along with the goods being shipped. In this case, the type ofcooling device 110 may also include dry ice (e.g., solid carbon dioxide)that may sublimate over time during transit of the packaging 100 and thegoods. The considerations as to whether to include or exclude the use ofthe cooling devices 110 described herein may include the type of goodsbeing shipped, the purchasers requested features of the packaging 100,the inclusion or exclusion of the bubble foil insulation layer 115,among other factors. Therefore, although FIG. 1 shows the packaging 100including a cooling device 110, a bubble foil insulation layer 115, andcondensation wicking layer 120, the inclusion or exclusion of theseitems may be selected based on the factors, among others, describedherein.

FIG. 2 is a block diagram of a packaging according to another exampleembodiment of the principles described herein. In an embodiment, thepackaging 200 may include an insulating wall 205. In the embodimentshown in FIG. 2 , the packaging 200 does not include a cooling device asshown and described in connection with FIG. 1 . In an example, thepackaging 200 may further include a box to encompass the insulating wall205.

The insulating wall 205 may be any type of wall that may help toinsulate a product from changes in temperature. In an example, theinsulating wall 205 may include a plurality of insulating walls 205 thatform a cube with an interior portion that is hollow. The interiorportion that forms this hollow, during use of the packaging 200,provides for an object to be held therein. The object may be any type ofobject including both products to be shipped and, specifically, productsthat may be damaged due to changes in temperature had the packaging 200not been present. By way of example, the product may be a chocolateproduct that, if subjected to an increase in temperature during transit,may melt damaging the quality and/or taste of the chocolate. By way ofanother example, the product may be a glass jar full of perishablefoodstuffs. In this example, it may be disadvantageous for the glass jarto be subjected to extremely cold temperatures sufficient to freeze theperishable foodstuffs therein and causing the glass jar to breakspilling the perishable foodstuffs in the packaging 200.

The insulating wall 205 may be made of any type of insulating material.In an example, the insulating wall 205 may be made of a foam. In anexample, the insulating wall 205 may be manufactured using any type ofexpansion foam that is presented in, for example, a form such as aliquid and is allowed to cure thereby creating an insulating wall 205according to the principles described herein. In the example embodimentmanufacturing processes described herein, the liquid foam may beinjected into the form after the form has been closed. As the expansivefoam is introduced into the form, the liquid expansive foam forms aroundone or more ribs, walls, and chamfer walls formed in the form and, aftercuring of the liquid expansive foam, a monolithic piece is formedtherein. At this point the form may be opened and the cured insulatingwall 205 or walls may be removed.

As shown in FIG. 2 , the packaging 200 may include a bubble foilinsulation layer 215. In an embodiment, the bubble foil insulation layer215 may include multiple layers that allow a gas or other fluid to beplaced within bubbled sections formed between the layers. In one exampleembodiment, the bubble foil insulation layer 215 is formed byoperatively coupling a flat polyethylene (LDPE) layer with a bubbledlayer of LDPE in order to trap a gas or other fluid between the layersof LDPE. The flat layer of LDPE may be sealed to the bubble layer ofLDPE so that the gas or other fluid does not escape. In this embodiment,a reflective foil layer may be operatively coupled to the flat layer ofLDPE. The reflective foil layer reduces radiant heat transmitted intothe package 200. In an embodiment, the flat surface of the bubble foilinsulation layer 215 that includes the flat layer of LDPE may be affixedto an outer surface of the at least one insulating wall 205. Theinclusion of the bubble foil insulation layer 215 prevents radiant heattransmission into and out of the hollow formed by the plurality ofinsulating walls 205 formed into the cube packaging 200 as describedherein. By including this bubble foil insulation layer 215, thetemperature within the packaging 200 may remain at a relatively constanttemperature over time as the packaging 200 is shipped from one locationto another. In an embodiment, the bubble foil insulation layer 215 maybe laminated on the outer surface of the plurality of insulating wall205 during the formation process of the insulating wall 205 by placing alayer of the bubble foil insulation layer 215 within the form used toform the insulating wall 205 prior to injection of the expansion foam.

As shown in FIG. 2 , the packaging 200 may include a condensationwicking layer 220. During use of the packaging 200, the packaging 200may be subjected to different temperatures, at different pressures, andat different dew points. These changes may result in the creation ofcondensation during transit of the packaging 200 as the packaging ismoved from land delivery vehicles, to delivery flights, and back again.The condensation wicking layer 220 may absorb an amount of condensationthereby preventing potential damage or spoiling of the products beingshipped. In an embodiment, the absorption rate and absorptioncapabilities of the condensation wicking layer 220 may be sufficient toprevent spoilage or damage of the product being shipped during theentire transit of that product.

The inclusion of the bubble foil insulation layer 215 on the outersurface of the insulating walls 205 and the condensation wicking layer220 on the inner surface of the insulating wall 205, the transit timeand distance may be extended. Due to the inclusion of the bubble foilinsulation layer 215, the temperature within the packaging 200 may bemaintained for a longer period of time. Due to the inclusion of thecondensation wicking layer 220, the changes in pressure, temperature,and dew point may be accommodated for allowing for more variedconditions under which the packaging 200 is subjected to and extendingthe duration of transit for the packaging 200.

In an embodiment, the packaging 200 may include the bubble foilinsulation layer 215 without the condensation wicking layer 220. Inanother embodiment, the packaging 200 may include the condensationwicking layer 220 without the bubble foil insulation layer 215. In yetanother embodiment, the packaging 200 may include both the condensationwicking layer 220 and the bubble foil insulation layer 215. Therefore,the inclusion or exclusion of either of the condensation wicking layer220 or bubble foil insulation layer 215 with the packaging 200 may bedriven by a number of factors including, but not limited to, thepurchasers shipping requirements, characteristic shipping requirementsassociated with the products being shipped in the packaging 200, as wellas weight considerations due to the inclusion or exclusion of either ofthe condensation wicking layer 220 or bubble foil insulation layer 215,among other factors.

Additionally, the present specification contemplates that the coolingdevice 210 may or may not be included within the packaging 200. Forexample, because the bubble foil insulation layer 215 provides anincrease insulative capabilities of the packaging 200, the insulatingwalls 205 may be made thinner. This may reduce the amount of spaceavailable within the thickness of the insulating walls 205 toincorporated a cooling device (not shown) therein. In this instance,other cooling devices may be placed within the hollow of the formedpackaging 200 along with the goods being shipped. In this case, the typeof cooling device may also include dry ice (e.g., solid carbon dioxide)that may sublimate over time during transit of the packaging 200 and thegoods. The considerations as to whether to include or exclude the use ofthe cooling devices 210 described herein may include the type of goodsbeing shipped, the purchasers requested features of the packaging 200,the inclusion or exclusion of the bubble foil insulation layer 215,among other factors. Therefore, although FIG. 2 shows the packaging 200including a bubble foil insulation layer 215, and condensation wickinglayer 220, the inclusion or exclusion of these items may be selectedbased on the factors, among others, described herein.

FIG. 3 is a flowchart showing a method 300 of forming at least oneinsulating wall of a packaging according to an example of the principlesdescribed herein. The method 300 may begin at block 305 with placing acooling device into a form used to create the insulating walls of thepackaging such as those described in connection with FIGS. 1 and 2 . Inan example the form may be sized such that any insulating wall is formedaround a cooling device after the form is closed at block 310. In anexample, a heating or cooking device may also be placed in the form inplace of the cooling device. In these examples, the heat from theheating or cooking device may maintain or increase the heat of anyobject placed within the packaging.

As described herein, a liquid form of expansive foam may be injectedinto the form at block 315. In an example, the form may include one ormore liquid foam inlets into which a type of liquid foam may be passed.In an example, the liquid foam may be a mixture of a polyether polyolresin and a polymeric isocyanate. The placement of the cooling device(s)or heating devices into the form may depend on the intended cooling (orheating) characteristics within the packaging. In an example, thecooling device may be placed such that the cooling device is placedgenerally center to each of the insulating walls as the curing of thefoam continues at block 320. Other placement options are possible andthe present specification contemplates those other placements of thecooling device within the form.

At block 305, in an embodiment, the method 300 may include placing aplastic wrap on the interior surfaces of the form prior to placing thecooling device in the form and prior to closing the form at block 310and injecting the liquid form of expansion foam into the form at block315. Placing plastic wrap on the interior surfaces of the form may bedone to allow the cured foam (e.g., cured at block 320) to release fromthe interior surfaces of the form. Additionally, the plastic wrap may beused as an exterior layer to the cured foam members created via themethod 300. After the foam is cured, the plastic and foam may be trimmedto a desired shape. Trimming may be accomplished using any type ofcutting tool including razor blades. In an example, the thickness of theplastic wrap is between 2 and 5 thousandths of an inch. In an example,the thickness of the plastic wrap is 4 thousandths of an inch. In anembodiment, the process of placing a plastic wrap on the interiorsurfaces of the form prior to placing the cooling device in the form andprior to closing the form may be eliminated and the condensation wickinglayer and bubble foil insulation layer described herein may be laminateddirectly onto the surface of the insulation walls.

In an example, the insulating walls may be formed via this method 300either individually or together based on the forms used during themethod 300 described herein. In an example, three walls may be formed inform at a time. In this example, the insulating walls placed within thebox may include two panels consisting of three walls each. The total ofsix walls forming the cuboid shape within the box may then be arrangedto surround a shipped product within the cardboard box.

In an example, a plastic sheeting may be added around all finished sidesof the cuboid shape. In this example, the plastic may be made of ahigh-density polyethylene (HDPE) having a thickness of between 0.010thousandths of an inch and 0.050 thousandths of an inch. In an example,the sheet of HDPE is 0.030 millimeters thick.

The form may be any form that creates the insulating wall as describedherein. In an example, the form may include a number of chamfered endssuch that the completed insulating walls include at least one chamferededge. In an example, the angle of the chamfered edge is 47 degreesrelative to, for example, an outer surface of the insulating wall. Thisallows a snug fit between panels of the insulating walls duringpackaging in order to ensure a tight fit between seams when theinsulating walls are assembled together.

The method 300, in an embodiment, may further include placing thefabricated insulating walls into a freezer. The freezer will freeze thecontents of the cooling devices embedded into the insulating walls inpreparation for use in packaging of objects and shipment. Any level offreezing or cooling of the cooling devices may be achieved based on oneor more factors including what is being shipped using the packaging,what temperature the object is to be maintained at, how the long thepackaging is to be in transit, among other factors.

FIG. 4 is a flowchart showing a method 400 of forming at least oneinsulating wall of a packaging according to another example embodiment,of the principles described herein. The method 400 may begin at block405 with placing a bubble foil insulation layer onto a first side of aform. In this embodiment, and in the embodiment described in connectionwith FIGS. 8A through 8C, the form may include a first side that isclosed onto a second side in order to provide a space into which aliquid form of expansive foam may be injected into the form as describedherein. In an embodiment, the first side of the form may be a side ofthe form used to form an outside surface of the insulating wallsdescribed herein. As such, the bubble foil insulation layer may be laidon the first side of the form so that when the liquid foam is injectedinto the form it is affixed or laminated onto the outside surface of theinsulating walls.

The method 400, at block 410, may also include placing a condensationwicking layer on a second side of the form. Again, in an embodiment andwith reference to the embodiments described in connection with FIGS. 8Athrough 8C, the form may include a first side that is closed onto asecond side in order to provide a space into which a liquid form ofexpansive foam may be injected into the form as described herein. In anembodiment, the second side of the form may be a side of the form usedto form an inside surface of the insulating walls described herein. Assuch, the condensation wicking layer may be laid on the second side ofthe form so that when the liquid foam is injected into the form it isaffixed or laminated onto the inside surface of the insulating walls. Asdescribed herein, the condensation wicking layer is placed in the formfor, at least two purposes. First, the presence of the condensationwicking layer may absorb any water that may result in the slight changesin temperature or pressure within the package as the package istransported from one location to another. Second the presence of thecondensation wicking layer in the form prevents the expansion foam, wheninjected into the form, from sticking to the interior surfaces of theform.

In an alternative embodiment, instead of placing a condensation wickinglayer on a second side of the form at block 410, a plastic film may beplaced on the second side of the form. Like the condensation wickinglayer, this plastic film may prevent any expanding foam from sticking tothe interior surfaces of the form when injected into the closed form.

In an embodiment, the method may also include placing a cooling deviceor a heating device into the form used to create the insulating walls ofthe packaging such as those described in connection with FIGS. 1 and 2 .However, according to this embodiment, the cooling devices and/orheating devices may not be added. In an example embodiment where thecooling devices and/or heating devices are placed within the form, thecooling devices and/or heating devices may be sized such that anyinsulating wall is formed around a cooling device and/or heating deviceafter the form is closed at block 415. In an example, a heating orcooking device may also be placed in the form in place of the coolingdevice. In these examples, the heat from the heating or cooking devicemay maintain or increase the heat of any object placed within thepackaging.

Whether a heating or cooking device and/or a cooling device is addedinto the form, the method 400 includes, at block 415, closing the form.In an embodiment, the form may include a latching mechanism that securesthe first side of the form to the second side of the form and in aclosed position. Because the liquid form of expansive foam expands, theform and its latches may prevent excessive leakage of the expanding foamand cause the foam to expand completely into the corners of voids withinthe closed form.

As described herein, the method includes injecting a liquid form ofexpansive foam into the form at block 420. In an example, the form mayinclude one or more liquid foam inlets into which a type of liquid foammay be passed. As described herein in an example embodiment, the liquidfoam may be a mixture of a polyether polyol resin and a polymericisocyanate. The placement of the cooling device(s) or heating devicesinto the form may depend on the intended cooling (or heating)characteristics within the packaging. In an example, the cooling devicemay be placed such that the cooling device is placed generally center toeach of the insulating walls as the curing of the foam continues atblock 425. Other placement options are possible and the presentspecification contemplates those other placements of the cooling devicewithin the form. In an embodiment, the injection of the expansion foammay occur prior to the closing of the form depending on the expansiveproperties of the expansion foam and time available

The method 400 may also include, at block 430, with removing the curedfoam form the form and trimming the foam where and if necessary. In anembodiment, the expansion foam may expand outside or between crackswithin the form. Here, the form may include spaces for the expansionfoam to expand into so that the walls may be completely formed. Becausethis extra expanded foam is attached to the cured walls, this may beremoved so that the walls may be sized to fit tightly as describedherein in order to maintain a temperature within the walls of thepackaging.

In an example, the insulating walls may be formed via this method 400either individually or together based on the forms used during themethod 400 described herein. In an example, three walls may be formed inform at a time. In this example, the insulating walls placed within thebox may include two panels consisting of three walls each. The total ofsix walls forming the cuboid shape within the box may then be arrangedto surround a shipped product within the cardboard box.

In an example, a plastic sheeting may be added around all finished sidesof the cuboid shape. In this example, the plastic may be made of ahigh-density polyethylene (HDPE) having a thickness of between 0.010thousandths of an inch and 0.050 thousandths of an inch. In an example,the sheet of HDPE is 0.030 millimeters thick. In this embodiment, thisplastic sheeting may be formed between the condensation wicking layerand the inner side of the insulating wall and/or between the bubble foilinsulation layer and the outer side of the insulating wall. Here, themethod may further include, at 410 with placing the plastic sheeting ontop of the bubble foil insulation layer and condensation wicking layerprior to the form being closed at block 415.

The form may be any form that creates the insulating wall as describedherein. In an example, the form may include one or more chamfered endssuch that the completed insulating walls include at least one chamferededge. In an example, the angle of the chamfered edge is 47 degreesrelative to, for example, an outer surface of the insulating wall. Thisallows a snug fit between panels of the insulating walls duringpackaging in order to assure a tight fit between seams when theinsulating walls are assembled.

The method 400, in an embodiment, may further include placing thefabricated insulating walls into a freezer in those embodiments wherethe cooling device is embedded into the insulating walls. The freezerwill freeze the contents of the cooling devices embedded into theinsulating walls in preparation for use in packaging of objects andshipment. Any level of freezing or cooling of the cooling devices may beachieved based on one or more factors including what is being shippedusing the packaging, what temperature the object is to be maintained at,how the long the packaging is to be in transit, among other factors. Inthe embodiment where a heating device is embedded within the insulatingwalls, the heating device may be activated prior to shipping of thepackaging.

FIG. 5 is a block diagram of a shipping container 500 according to anexample of the principles described herein. The shipping container 500may include a box 530, a plurality of insulating walls 505, and, atleast one, cooling device and/or heating device 525. As describedherein, the shipping container 500 may include either or both of acooling device or a heating device in order to control or maintain atemperature or range of temperatures within the insulating walls 505formed into a cubic shape with a hollow therein to place an item to beshipped.

The box 530 may be any type of box that can hold an assembly of theplurality of insulating walls 505 together as described herein. In anexample, the box 530 may be made of cardboard similar to those used inthe package delivery services. This box 530 may also impart a level ofinsulation to the insulating walls 505 in order to prevent the transferof heat into and/or out of the shipping container 500. In an example,the box 530 may also impart a level of rigidity to the assembly ofinsulating walls 505 as described herein. In an example, the box 530 maybe made of corrugated cardboard having a c-flute interior having andedge crush test (ECT) of 32 or greater.

The insulating walls 505 may be similar to those insulating walls (FIG.1, 105 ) described in connection with FIG. 1 . The insulating walls 505may be any type of wall that may help to insulate a product from changesin temperature. In an example, each of the insulating walls 310 may bebetween 1.5-3 inches at its thickets point. The insulating walls 505 mayhave an R-value of 5 in an example embodiment.

The plurality of insulating walls 505 may be formed with each of theinsulating walls 505 being a wall of a cube. The formed cube includes acubic-void therein formed by the insulating walls 505 such that anobject may be placed therein. The cubic-void formed within theinsulating walls 505 may vary in size depending on the thickness of theinsulating walls 505, the height and width of the insulating walls 505,a temperature to be maintained within the inner void, and the item to beshipped in the shipping container 500, among other factors. The objectto be shipped in the shipping container 500 may include any type ofobject that may be protected from changes in temperature as the shippingcontainer 500 is shipped from its originating location to itsdestination. This is true for either objects that are to be held at arelatively high temperature compared to the temperature exterior to thebox 530 or objects that are to be held at a relatively low temperaturecompared to the temperature exterior to the box 530.

As described herein, the insulating walls 505 may each have a chamferformed at least one edge of the insulating walls 505. In an example, theangle of the chamfer may be between 40 and 55 degrees relative to aplanar surface of the insulating walls 505 that butts against the box305 as described herein. In an example, the angle of the chamfer may be47 degrees relative to a planar surface of the insulating walls 505 thatbutts against the box 530 as described herein. In an example, each ofthe edges of each of the insulating walls 505 may have an angle of 47degrees. By setting the angle to this specific degree, the temperaturewithin the cube formed by the insulating walls 505 may be maintainedbetter relative to other angles. In an example, a lid may be formed outof one of the insulating walls 505 to provide access to a user into thecenter of the insulating walls 505. This lid may have a thickness ofbetween 1 to 3 inches. In an example, the thickness of all insulatingwalls 505 is between 1 to 3 inches. In an example, the thickness of thelid may be 1.5 inches. In an example, the thickness of all insulatingwalls is 1.5 inches.

The cooling device and/or heating device 525 may be any type of coolingdevice or heating device that can help to maintain a temperature leveland/or a range of temperatures within the box 530 during transit. Asdescribed herein, a heating device may be used to help maintain atemperature within the box 530. For ease of explanation, however, thepresent example will be described in connection with implementing acooling device and/or heating device 525.

Where applicable, the cooling device may be any type of cooling device.In an example, the cooling device may include a bag with the bag full ofa crystal polymer and liquid such as water. In this example embodiment,2-3 grams of the crystal polymer may be added to 26-30 ounces of water.As described herein, the cooling device may be formed into at least oneof the insulating walls 505. This may be done by placing the coolingdevice into a form. The form may have an interior sufficient to allow anexpansion foam to be introduced and form the insulating walls 505. Asthe expansion foam expands within the form, the cooling device isembedded into the formed insulating walls 505.

As shown in FIG. 5 , the shipping container 500 may include a bubblefoil insulating layer 515. In an embodiment, the bubble foil insulatinglayer 515 may include multiple layers that allow a gas or other fluid tobe placed within bubbled sections formed between the layers. In oneexample embodiment, the bubble foil insulating layer 515 is formed byoperatively coupling a flat polyethylene (LDPE) layer with a bubbledlayer of LDPE in order to trap a gas or other fluid between the layersof LDPE. The flat layer of LDPE may be sealed to the bubble layer ofLDPE so that the gas or other fluid does not escape. In this embodiment,a reflective foil layer may be operatively coupled to the flat layer ofLDPE. The reflective foil layer reduces radiant heat transmitted intothe shipping container 500. In an embodiment, the flat surface of thebubble foil insulating layer 515 that includes the flat layer of LDPEmay be affixed to an outer surface of the at least one insulating wall505. The inclusion of the bubble foil insulating layer 515 preventsradiant heat transmission into and out of the hollow formed by theplurality of insulating walls 505 formed into the shipping container 500as described herein. By including this bubble foil insulating layer 515,the temperature within the shipping container 500 may remain at arelatively constant temperature over time as the shipping container 500is shipped from one location to another. In an embodiment, the bubblefoil insulating layer 515 may be laminated on the outer surface of theplurality of insulating walls 505 during the formation process of theinsulating walls 505 by placing a layer of the bubble foil insulatinglayer 515 within the form used to form the insulating walls 505 prior toinjection of the expansion foam.

As shown in FIG. 5 , the shipping container 500 may include acondensation wicking layer 520. During use of the shipping container500, the shipping container 500 may be subjected to differenttemperatures, at different pressures, and at different dew points. Thesechanges may result in the creation of condensation during transit of theshipping container 500 as the shipping container 500 is moved from landdelivery vehicles, to delivery flights, and back again. The condensationwicking layer 520 may absorb an amount of condensation therebypreventing potential damage or spoiling of the products being shipped.In an embodiment, the absorption rate and absorption capabilities of thecondensation wicking layer 520 may be sufficient to prevent spoilage ordamage of the product being shipped during the entire transit of thatproduct.

With the inclusion of the bubble foil insulating layer 515 on the outersurface of the insulating walls 505 and the condensation wicking layer520 on the inner surface of the insulating walls 505, the transit timeand distance may be extended. Due to the inclusion of the bubble foilinsulating layer 515, the temperature within the shipping container 500may be maintained for a longer period of time. Due to the inclusion ofthe condensation wicking layer 520, the changes in pressure,temperature, and dew point may be accommodated for allowing for morevaried conditions under which the shipping container 500 is subjected toas well as extending the duration of transit for the shipping container500.

FIG. 6 is a side cut-away view of an insulating wall 605 according to anexample embodiment of the principles described herein. Although FIG. 6shows a single insulating wall 605, the present specificationcontemplates the use of a plurality of insulating walls 310 and in someexamples, insulating walls 605 that are coupled together at the chamfer645 edges. In this example, a hinge may be formed at the terminal endsof the insulating wall 605 where the chamfer 645 has been formed.

The insulating wall 605 may have first side of the insulating wall 635and a second side of the insulating wall 640. The first side of theinsulating wall 635 forms part of an interior wall within the box.Having six interior walls formed by six insulating walls 605, forexample, creates a void within the six insulating walls 605 allowing forthe placement of the object or product as described herein. The secondside of the insulating wall 640 is to abut an interior surface of atleast one side of the box or other outer surface as described in anexample embodiment herein. In an example embodiment, the second side ofthe insulating wall 640 may be laminated with a bubble foil insulatinglayer 615. In an embodiment, the bubble foil insulating layer 615 mayinclude multiple layers that allow a gas or other fluid to be placedwithin bubbled sections formed between the layers. In one exampleembodiment, the bubble foil insulating layer 615 is formed byoperatively coupling a flat LDPE layer with a bubbled layer of LDPE inorder to trap a gas or other fluid between the layers of LDPE. The flatlayer of LDPE may be sealed to the bubble layer of LDPE so that the gasor other fluid does not escape. In this embodiment, a reflective foillayer may be operatively coupled to the flat layer of LDPE. Thereflective foil layer reduces radiant heat transmitted into the shippingcontainer. In an embodiment, the flat surface of the bubble foilinsulating layer that includes the flat layer of LDPE may be affixed toan outer surface of the second side of the insulating wall 640. Theinclusion of the bubble foil insulating layer 615 prevents radiant heattransmission into and out of the hollow formed by the plurality ofinsulating wall 605 formed into the shipping container as describedherein. By including this bubble foil insulating layer 615, thetemperature within the shipping container may remain at a relativelyconstant temperature over time as the shipping container is shipped fromone location to another. In an embodiment, the bubble foil insulatinglayer 615 may be laminated on the outer surface of the plurality of thesecond side of the insulating wall 640 during the formation process ofthe insulating wall 605 by placing a layer of the bubble foil insulatinglayer 615 within the form used to form the insulating wall 605 prior toinjection of the expansion foam.

The first side of the insulating wall 635 may also include acondensation wicking layer 620 laminated onto the surface of the firstside of the insulating wall 635. During use of the shipping container,the shipping container may be subjected to different temperatures, atdifferent pressures, and at different dew points. These changes mayresult in the creation of condensation during transit of the shippingcontainer as the shipping container is moved from land deliveryvehicles, to delivery flights, and back again. The condensation wickinglayer 620 may absorb an amount of condensation thereby preventingpotential damage or spoiling of the products being shipped. In anembodiment, the absorption rate and absorption capabilities of thecondensation wicking layer 620 may be sufficient to prevent spoilage ordamage of the product being shipped during the entire transit of thatproduct.

With the inclusion of bubble foil insulating layer 615 on the surface ofsecond side of the insulating wall 640 and the condensation wickinglayer 620 on the surface of the first side of the insulating wall 635,the transit time and distance may be extended. Due to the inclusion ofthe bubble foil insulating layer 615, the temperature within theshipping container may be maintained for a longer period of time. Due tothe inclusion of the condensation wicking layer 620, the changes inpressure, temperature, and dew point may be accommodated for allowingfor more varied conditions under which the shipping container issubjected to as well as extending the duration of transit for theshipping container.

In an embodiment, with six insulating walls 605, the insulating walls605 form a cube or other type of polyhedron having six sides that mayfit into a box, a packaging, or other shipping container. In thisexample embodiment, a void may be created within the six sides of theinsulating walls 605 used to house the product or item being shipped viathe shipping container.

FIG. 6 also indicates that the chamfer 645 at the edge of the insulatingwall 605. The chamfer 645 may have an angle (θ). The angle (θ) may be ofany angle relative to the second side of the insulating wall 640 and/orthe first side of the insulating wall 635. As described herein, theangle (θ) may be 47 degrees relative to the second side 415. In anembodiment, the angle of the chamfer 645 may be measured from a 90°angle relative to the second side of the insulating wall 640 and/orbubble foil insulating layer 615. In this example, the angle (θ) of thechamfer 645 is about 137° relative to the planar surface of the secondside of the insulating wall 640 as shown in FIG. 6 . In an embodiment,the angle (θ) of the chamfer 645 is about 223° relative to the planarsurface of the first side of the insulating wall 635. By making thechamfer 645 grater than 45° relative to a perpendicular angle formedfrom the second side of the insulating wall 640, a snug fit betweenpanels of the insulating walls may be realized. Indeed, this ensures atight fit between seams when the insulating walls are assembledpreventing heat transmission from outside the shipping container intothe shipping container. In this embodiment, as the six insulating wall605 are assembled a pressure between the ends of the insulating walls605 where the chamfer 645 is created may be overcome thereby compressingthese ends together in order to form the cubic shape of the shippingcontainer.

FIG. 7 is a plan view of a plurality of insulating walls 705 accordingto an example of the principles described herein. In this example, theinsulating walls 705 may each be coupled together at their edges via awall hinge 750 as described herein. In this example, the wall hinges 750allow each of the insulating walls 705 to be connected while beingformed into a cube or, generally, a six-sided polyhedron if thedimensions of the insulating walls 705 are not square.

In the example shown in FIG. 7 , the insulating walls 705 may be bent atthe wall hinges 750 in order to form the interior void to house theobject or product to be shipped. The insulating walls 705 thus formed,may then be placed within a box such as a cardboard box. In thisexample, the interior surfaces of the box may abut the exterior surfacesof the insulating walls 705 or the second sides (e.g., FIG. 6, 640 ) ofeach of the insulating walls 705. In this manner, a shippable containermay be produced that allows a perishable product to be transportedwithout being subjected to changes in temperature. As such, productssuch as frozen goods, chocolates, among others may be shipped withoutbeing destroyed by, for example, the temperature outside of the shippingcontainer and/or box.

Although FIG. 7 shows all six insulating walls 705 being coupledtogether using a wall hinge 750, this is meant as an example only.Indeed, the present specification contemplates that any number ofinsulating walls 705 may or may not be coupled together in any form. Inan example, the six insulating walls 705 may be coupled together to formtwo different pieces such that the two pieces can be formed together tocreate the polyhedron as described herein.

As described herein, the insulating walls 705 may have a condensationwicking layer formed onto a first side of the insulating wall and abubble foil insulating layer formed on a second side of the insulatingwall as described herein in connection with FIG. 6 . Although FIG. 7does not show these layers, the present specification contemplates thatthe insulating walls 705 may include either or both the bubble foilinsulating layer and condensation wicking layer.

FIG. 8A is a top view of an open form 800 used to form the insulatingwalls according to an example of the principles described herein. Theform 800 may include a form lid 805 and a form base 810.

The form lid 805 may have a flat interior surface that interfaces withthe form base 810 when in a closed state. This flat interior surface ofthe form lid 805 may interface with the form base 810 in order to formthe second side (FIG. 6, 640 ) of the insulating walls as describedherein.

In an example, the form lid 805 may further include one or more liquidexpansion foam holes 840 into which a user may introduce the liquidexpansion foam as described herein. The liquid expansion foam may cureas it is pumped into the closed form 800. The form lid 805 may alsoinclude one or more form hinges 835 that allow the form 800 to beclosed.

The form base 810 may include one or more form wells 820 defined by oneor more form walls 815. The form walls 815 may each have a chamfer wall830 next to it. The chamfer walls 830 create the chamfer (FIG. 6, 645 )of the insulating walls described herein. Although the form 800 showsthat each form wall 815 includes a chamfer wall 830, it can beappreciated that any number of chamfer walls 830 can be eliminated tocreate a non-chamfered wall. FIGS. 8A-8C show four form wells 820 usedto form four walls of a packaging described herein. Although thesefigures show only four form wells 820, it is appreciated that the form800 may include more than four or less than four form wells 820 used toform one or more insulating walls as described herein. In an embodiment,a form 800 may be used to form a portion of a six-sided packaging. Thisportion may include a subset of six insulating walls that, when matchedup with a complimentary number of insulating walls forms the cuboidalshape of the packaging. In an embodiment, the form 800 may include sixform wells 820 used to form six connected insulating walls each used toform a side of the insulating walls of the packaging. Additionally, inan embodiment, the size and shape of the form wells 820 may be differentfrom other form wells 820 such that the size and shape of the insulatingwalls may form different sizes of insulating walls.

The form base 810 may also include one or more form ribs 825 that alsohelp to form the chamfer (FIG. 6, 645 ) of the insulating wallsdescribed herein. In an example, some or all of the form ribs 825 mayextend as tall as the form walls 815 and therefore interface with theform lid 805 when the form 800 is closed. In this example, no space isprovided between a tallest portion of the form ribs 825 and the form lid805 thereby preventing the wall hinges (e.g., FIG. 7, 750 ) between theinsulating walls described herein from being formed. In an example, somespace is provided between a tallest portion of the form ribs 825 and theform lid 805 thereby creating the hinges (FIG. 7, 750 ) between theinsulating walls described herein.

In an example, a plastic sheeting may be laid on top of the surface theincludes, at least, the form wells 820, form walls 815, and form ribs825. In this example, a second sheet of plastic may be laid on thebottom side of the form lid 805 that interfaces with the form base 810and may include holes that match the liquid expansion foam holes 840.During use, the two plastic sheets may prevent the liquid expansionfoam, when injected, from sticking to the surfaces of the form 800. Inother embodiments, this plastic sheeting may be replaced or supplementedwith the use of the condensation wicking layer and bubble foilinsulating layer.

FIG. 8B is a top view of an open form 800 used to form the insulatingwalls according to another example embodiment of the principlesdescribed herein. FIG. 8B may be similar to FIG. 8A in that the form 800also includes a form lid 805 with a form base 810 operatively coupled tothe form lid 805 via one or more form hinges 835.

Similar to FIG. 8A, the form lid 805 of FIG. 8B may include one or moreliquid expansion foam holes 840 formed therein to receive a liquidexpansive foam. Additionally, the form base 810 of FIG. 8B may includethe form walls 815, form wells 820, form ribs 825, and chamfer walls 830that are used to also form one or more insulating walls as described inconnection with FIG. 8A.

FIG. 8B also shows that a bubble foil insulating layer 850 has been laidonto the surface of the form lid 805. The bubble foil insulating layer850 is shown overlaying the form lid 805 with the form lid 805 beingshown in ghost with dashed lines. Here, the bubble foil insulating layer850 may include multiple layers that allow a gas or other fluid to beplaced within bubbled sections formed between the layers. In one exampleembodiment, the bubble foil insulating layer 850 is formed byoperatively coupling a flat LDPE layer with a bubbled layer of LDPE inorder to trap a gas or other fluid between the layers of LDPE. The flatlayer of LDPE may be sealed to the bubble layer of LDPE so that the gasor other fluid does not escape. In this embodiment, a reflective foillayer may be operatively coupled to the flat layer of LDPE. Thereflective foil layer reduces radiant heat transmitted into the package.

In an embodiment, the flat surface of the bubble foil insulating layer850 that includes the flat layer of LDPE may be affixed to an outersurface of the at least one insulating wall. The inclusion of the bubblefoil insulating layer 850 prevents radiant heat transmission into andout of the hollow formed by the plurality of insulating walls formedinto the cube packaging as described herein. By including this bubblefoil insulating layer 850, the temperature within the packaging mayremain at a relatively constant temperature over time as the packagingis shipped from one location to another. In an embodiment, the bubblefoil insulating layer 850 may be laminated on the outer surface of theplurality of insulating walls during the formation process of theinsulating wall by placing a layer of the bubble foil insulating layer850 within the form 800 used to form the insulating wall prior toinjection of the expansion foam. In this embodiment, the bubbled side ofthe bubble foil insulating layer 850 may be placed against the surfaceof the form lid 805 so that the flat layer of LDPE is affixed orlaminated onto the second side of the insulation layer when the liquidexpansive foam is introduced into the closed form 800. In an embodiment,the bubble foil insulating layer 850 may include one or more holes thatmatch the layout of the liquid expansion foam holes 840 formed on theform lid 805. In another example embodiment, one or more holes may beformed through the bubble foil insulating layer 850 at the locations ofthe liquid expansion foam holes 840 after the bubble foil insulatinglayer 850 has been placed against the form lid 805.

In the embodiment shown in FIG. 8B, the bubble foil insulating layer 850may be used to form the insulating walls in the form 800 with or withoutthe inclusion of a condensation wicking layer. Therefore, the exampleembodiments include those embodiments where the bubble foil insulatinglayer 850 is included without the condensation wicking layer, where thebubble foil insulating layer 850 is included with the condensationwicking layer, and where the bubble foil insulating layer 850 is notinclude where the condensation wicking layer is included.

FIG. 8C is a top view of an open form 800 used to form the insulatingwalls according to another example embodiment of the principlesdescribed herein. FIG. 8C may be similar to FIGS. 8A and 8B in that theform 800 also includes a form lid 805 with a form base 810 operativelycoupled to the form lid 805 via one or more form hinges 835.

Similar to FIGS. 8A and 8B, the form lid 805 of FIG. 8C may include oneor more liquid expansion foam holes 840 formed therein to receive aliquid expansive foam. Additionally, the form base 810 of FIG. 8C mayinclude the form walls 815, form wells 820, form ribs 825, and chamferwalls 830 that are used to also form one or more insulating walls asdescribed in connection with FIGS. 8A and 8B.

As described herein, the form base 810 may be overlaid with acondensation wicking layer 845. In this embodiment, the bubble foilinsulating layer 850 is shown overlaying the form lid 805 with the formlid 805 being shown in ghost with dashed lines much like in FIG. 8B.Similarly, the condensation wicking layer 845 is shown overlaying theform base 810 with the form base 810 being shown in ghost with dashedlines. As described herein, the packaging formed via the insulatingwalls may be subjected to different temperatures, at differentpressures, and at different dew points. These changes may result in thecreation of condensation during transit of the packaging as thepackaging is moved from land delivery vehicles, to delivery flights, andback again. The condensation wicking layer 845 may absorb an amount ofcondensation thereby preventing potential damage or spoiling of theproducts being shipped. In an embodiment, the absorption rate andabsorption capabilities of the condensation wicking layer 845 may besufficient to prevent spoilage or damage of the product being shippedduring the entire transit of that product.

In the embodiment shown in FIG. 8C, the bubble foil insulating layer 850may be used to form the insulating walls in the form 800 with or withoutthe inclusion of a condensation wicking layer 845. Therefore, theexample embodiments include those embodiments where the bubble foilinsulating layer 850 is included without the condensation wicking layer845, where the bubble foil insulating layer 850 is included with thecondensation wicking layer 845, and where the bubble foil insulatinglayer 850 is not include where the condensation wicking layer 845 isincluded.

The inclusion of the condensation wicking layer 845 on the outer surfaceof the insulating walls (e.g., second side of the insulating walls) andthe condensation wicking layer 845 on the inner surface (e.g., firstside of the insulating wall) of the insulating walls, the transit timeand distance may be extended. Due to the inclusion of the bubble foilinsulating layer 850, the temperature within the packaging may bemaintained for a longer period of time. Due to the inclusion of thecondensation wicking layer 845, the changes in pressure, temperature,and dew point may be accommodated for allowing for more variedconditions under which the packaging is subjected to as well asextending the duration of transit for the packaging.

In an embodiment, the formed packaging formed by arranging theinsulating walls after removing the cured insulating walls from the formmay include additional packaging materials. For example, before theformed insulating walls are placed in a cardboard box, the outsideand/or inside of the insulating walls 105 may be lined by butcher paper.In this embodiment, the butcher paper may be aesthetically appealing toa recipient of the package such as when the package is used to transportfrozen or fresh meats. In addition to providing an aesthetic appeal tothe package, the butcher paper may be recyclable such that the packageif relatively more eco-friendly. In an embodiment, the butcher paper mayinclude promotional markings specific to the shipper, the customer, thecompany providing the goods, or other entities.

FIG. 9 is a top plan view of the packaging 900 according to anotherexample of the principles described herein. The packaging 900 mayinclude, in this example, six insulating walls 905, and a box (e.g.,FIG. 3, 305 ) to hold the six insulating walls 905 therein. In thisexample embodiment, each of the insulating walls 905 includes a coolingdevice 910 as described herein. However, the present specificationcontemplates that the insulating walls 905 may or may not include acooling device 910 and may or may not include a heating device asdescribed herein. Although FIG. 9 shows a packaging 900 having sixinsulating walls 905 with each insulating wall 905 having a coolingdevice 910, the present specification contemplates that any number ofthe insulating walls 905 may include a cooling device 910 embeddedtherein. Additionally, more than six insulating walls 905 may beincluded that fit within the void defined by the insulating walls 905shown in FIG. 9 such that different objects placed within the void inpreparation for transit may be separated and further insulated betweeneach other.

The packaging 900 further includes a box (e.g., FIG. 3, 305 ) asdescribed herein. The box may provide stability to the insulating walls(FIG. 3, 310 ) held therein as well as provide additional insulation tothe insulating walls 905. The box may include one nor more flaps 905.The flaps 905 may be used to close the packaging 900 after a topinsulating wall 905 is closed in onto the other insulating walls 905creating the void therein.

FIG. 9 shows each of the cooling devices 910 as being embedded generallyin a central location within each of the insulating walls 905. However,the present specification contemplates the embedding of the coolingdevices 910 within any portion of the insulating walls 905 to achieveany localized cooling (or heating) effects on the object as it is placedin the void.

As shown in FIG. 9 , the packaging 900 may include a bubble foilinsulating layer 915. In an embodiment, the bubble foil insulating layer915 may include multiple layers that allow a gas or other fluid to beplaced within bubbled sections formed between the layers. In one exampleembodiment, the bubble foil insulating layer 915 is formed byoperatively coupling a flat LDPE layer with a bubbled layer of LDPE inorder to trap a gas or other fluid between the layers of LDPE. The flatlayer of LDPE may be sealed to the bubble layer of LDPE so that the gasor other fluid does not escape. In this embodiment, a reflective foillayer may be operatively coupled to the flat layer of LDPE. Thereflective foil layer reduces radiant heat transmitted into thepackaging 900. In an embodiment, the flat surface of the bubble foilinsulation layer 115 that includes the flat layer of LDPE may be affixedto an outer surface of the at least one insulating wall 905. In theexample embodiment shown in FIG. 9 , the bubble foil insulating layer915 is formed on the outside surface of each of the insulating walls 905including the lid insulating wall 905 shown. Additionally, the bubblefoil insulating layer 915 may be sandwiched in between the outer surfaceof the insulating walls 905 and the inner surface of the box into whichthe insulating walls 905 are placed.

The inclusion of the bubble foil insulating layer 915 prevents radiantheat transmission into and out of the hollow formed by the plurality ofinsulating walls 905 formed into the packaging 900 as described herein.By including this bubble foil insulating layer 915, the temperaturewithin the packaging 900 may remain at a relatively constant temperatureover time as the packaging 900 is shipped from one location to another.In an embodiment, the bubble foil insulating layer 915 may be laminatedon the outer surface of the plurality of insulating walls 905 during theformation process of the insulating walls 905 by placing a layer of thebubble foil insulating layer 915 within the form (e.g., FIGS. 8A-8C, 800) used to form the insulating walls 905 prior to injection of theexpansion foam.

As shown in FIG. 9 , the packaging 900 may include a condensationwicking layer 920. During use of the packaging 900, the packaging 900may be subjected to different temperatures, at different pressures, andat different dew points. These changes may result in the creation ofcondensation during transit of the packaging 900 as the packaging 900 ismoved from land delivery vehicles, to delivery flights, and back again.The condensation wicking layer 920 may absorb an amount of condensationthereby preventing potential damage or spoiling of the products beingshipped. In an embodiment, the absorption rate and absorptioncapabilities of the condensation wicking layer 920 may be sufficient toprevent spoilage or damage of the product being shipped during theentire transit of that product.

The inclusion of the bubble foil insulating layer 915 on the outersurface of the insulating walls 905 and the condensation wicking layer920 on the inner surface of the insulating walls 905, the transit timeand distance may be extended. Due to the inclusion of the bubble foilinsulating layer 915, the temperature within the packaging 900 may bemaintained for a longer period of time. Due to the inclusion of thecondensation wicking layer 920, the changes in pressure, temperature,and dew point may be accommodated for allowing for more variedconditions under which the packaging 900 is subjected to as well asextending the duration of transit for the packaging 900.

The specification and figures describe a packaging that includes one ormore insulating walls having a cooling device embedded therein. Thepackaging provides for the transport of any object including perishableobjects that may be susceptible to changes in temperatures. The packinghaving the cooling devices embedded therein allows for the void createdby the insulating walls to be used solely for the provision of placingobjects therein.

The blocks of the flow diagrams of FIGS. 3 and 4 as well as theprocesses described in connection with FIGS. 8A through 8C or steps andaspects of the operation of the embodiments herein and discussed hereinneed not be performed in any given or specified order. It iscontemplated that additional blocks, steps, or functions may be added,some blocks, steps or functions may not be performed, blocks, steps, orfunctions may occur contemporaneously, and blocks, steps or functionsfrom one flow diagram may be performed within another flow diagram.

The preceding description has been presented to illustrate and describeexamples of the principles described. This description is not intendedto be exhaustive or to limit these principles to any precise formdisclosed. Many modifications and variations are possible in light ofthe above teaching.

What is claimed is:
 1. A packaging comprising: at least one insulatingwall; at least one cooling device embedded into the at least one wall,the cooling device and at least one insulating wall forming a monolithicpiece; a bubble foil insulation layer formed on an outside surface ofthe at least one insulating wall; and a condensation wicking layerformed on an inside surface of the at least one insulating wall.
 2. Thepackaging of claim 1, wherein the at least one insulating wall comprisessix walls.
 3. The packaging of claim 1, wherein the bubble foilinsulation layer is laminated onto the outer surface of the at least oneinsulating wall.
 4. The packaging of claim 1, further comprising acardboard layer exterior to the at least one insulating wall forming anoutside layer of the packaging.
 5. The packaging of claim 1, wherein theat least one cooling device includes a plurality of cooling devicesembedded into a plurality of insulating walls.
 6. The packaging of claim1, wherein the condensation wicking layer is laminated onto the interiorsurface of the at least one insulating wall.
 7. The packaging of claim 1further comprising a plurality of bubbles formed in the bubble foilinsulation layer to maintain a polyatomic gas therein.
 8. The packagingof claim 1, wherein the at least one cooling device is embedded into theat least one insulating wall using a form to receive a liquid form ofexpansion foam through access holes defined trough one of the bubblefoil insulation layer and condensation wicking layer.
 9. A method offorming at least one insulating wall of a package, comprising: placing acooling device into a form, the form including a plurality of wellsdefined by a number of chamfered walls and ribs to form a plurality ofinsulating walls of an insulating package and hinges between theplurality of the insulating walls; placing a bubble foil insulationlayer on a first side of the form; placing a condensation wicking layeron a second side of the form closing the first side of the form onto thesecond side of the form; injecting a liquid form of an expansive foambetween the bubble foil insulation layer and condensation wicking layerand into the wells; and curing the foam to create the plurality ofinsulating walls having the cooling device embedded in at least one ofthe plurality of insulating walls, the cooling device and the at leastone of the insulating walls forming a monolithic piece.
 10. The methodof claim 9 further comprising forming holes into one of the bubble foilinsulation layer and condensation wicking layer through which the liquidform of the expansive foam may be passed into the wells.
 11. The methodof claim 10 further comprising trimming a portion of the bubble foilinsulation layer and the condensation wicking layer from a portion ofthe insulating wall.
 12. The method of claim 9, wherein the form formsat least two sides of a cube.
 13. The method of claim 9 furthercomprising forming a plurality of walls in the form to form a cubehaving a hollow portion to hold an object and forming a cardboard boxaround the plurality of walls.
 14. The method of claim 9, wherein atleast one edge of a plurality of abutting insulating walls have a47-degree chamfer.
 15. A shipping container, comprising: a box; sixinsulating walls, at least one side of each of the insulating walls laidagainst the surface of at least one wall of the box, each of theinsulating walls comprising: four chamfered edges; and at least onehinge between one of the four chamfered edges of a first insulating walland a chamfered edge of a second insulating wall, the chamfered edgebeing a 47-degree chamfer; a bubble foil insulation layer formed onto anouter surface of each of the insulating walls; and a condensationwicking layer formed onto an inner surface of each of the insulatingwalls.
 16. The shipping container of claim 15, wherein the sixinsulating walls forms a cube within the box, the cube comprising aninterior cavity to hold an object.
 17. The shipping container of claim15, wherein closing of the box causes pressure to be exerted on each ofthe interfaces between each of the six insulating walls creating aforced fit between each of the six insulating walls.
 18. The shippingcontainer of claim 15, wherein the box is made of cardboard.
 19. Theshipping container of claim 15, where each of the six insulating wallsis made of a mixture of a polyether polyol resin and a polymericisocyanate.
 20. The shipping container of claim 20 further comprisingforming holes into one of the bubble foil insulation layer andcondensation wicking layer through which the liquid form of theexpansive foam may be passed into the wells.
 21. The shipping containerof claim 21 further comprising a plurality of bubbles formed in thebubble foil insulation layer to maintain a polyatomic gas therein.